Thermal bridgebreaker and seal features in a thin-walled vacuum insulated structure

ABSTRACT

A vacuum insulated refrigerator structure includes an outer wrapper having a first opening and a first edge extending around the first opening. A liner has a second opening and second edge extending around the second opening. The liner is disposed inside the wrapper with the first and second edges being spaced apart to form a gap therebetween. An insulating thermal bridge extends across the gap, and an airtight vacuum cavity is formed between the wrapper and the liner. The thermal bridge includes elongated first and second channels having sealant disposed therein, and the first and second edges are disposed in the first and second channels, respectively. Porous core material may be disposed in the vacuum cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/312,641, filed Dec. 21, 2018, entitled “THERMALBRIDGEBREAKER AND SEAL FEATURES IN A THIN-WALLED VACUUM INSULATEDSTRUCTURE,” which is a National Stage Application under 35 U.S.C. § 371of International Patent Application No. PCT/US2016/043991, filed Jul.26, 2016, entitled “THERMAL BRIDGEBREAKER AND SEAL FEATURES IN ATHIN-WALLED VACUUM INSULATED STRUCTURE,” the entire disclosures of whichare hereby incorporated herein by reference.

BACKGROUND

The present device generally relates to insulated structures, and inparticular to a vacuum insulated refrigerator cabinet that includes athermal bridge breaker and seal that interconnects a wrapper and aliner.

Various types of insulated refrigerator cabinet structures have beendeveloped. One type of insulated structure includes a wrapper and aliner. The wrapper and liner are spaced apart to form an internalcavity, and the cavity is filled with polyurethane foam or otherinsulating material. Vacuum insulated refrigerator structures have alsobeen developed. Vacuum insulated refrigerator structures may include awrapper and a liner that define a cavity therebetween. The cavity may befilled with a vacuum insulated core material. Known refrigerator cabinetstructures may suffer from various drawbacks, including transfer of heatfrom the wrapper to the liner.

SUMMARY

In at least one aspect, the present disclosure includes a method ofmaking a vacuum insulated refrigerator structure. The method includesforming a wrapper from a sheet of material whereby the wrapper has afirst opening and a first edge extending around the first opening. Aliner is formed from a sheet of material. The liner has a second openingand a second edge extending around the second opening. The liner ispositioned inside the wrapper with the first and second edges beingspaced apart to form a gap therebetween. A cavity is formed between thewrapper and the liner. An insulating thermal bridge is positioned acrossthe gap. The thermal bridge includes elongated first and secondchannels, and the first and second edges are inserted into the first andsecond channels, respectively. Curable sealant is positioned in thefirst and second channels. The curable sealant may extend around, andencapsulate, the first and second edges to seal the cavity. The firstand/or second channels may include one or more protrusions or bosses onside surfaces of the channels to position the edges at a central portionof the channel and form gaps between the edges and the side surfaces ofthe channels. The gaps may be filled with curable sealant. The methodincludes causing porous material to at least partially fill the cavitybetween the wrapper and the liner. The porous material may comprise oneor more core panels that are positioned between the wrapper and theliner prior to positioning of the insulated thermal bridge across thegap between the wrapper and the liner. Alternatively, the porousmaterial may comprise powder or other suitable loose material that isintroduced into the cavity after the thermal bridge is positioned acrossthe gap. A vacuum is formed in the cavity, and the cavity is sealed tomaintain the vacuum.

In at least another aspect, a vacuum insulated refrigerator structureincludes an outer wrapper having a first opening and a first edgeextending around the first opening. A liner has a second opening andsecond edge extending around the second opening. The liner is disposedinside the wrapper with the first and second edges being spaced apart toform a gap therebetween. A vacuum cavity is formed between the wrapperand the liner. An insulating thermal bridge extends across the gap. Thethermal bridge includes elongated first and second channels, and thefirst and second edges are disposed in the first and second channels,respectively. Sealant is disposed in the first and second channels toseal the vacuum cavity and maintain a vacuum in the vacuum cavity.Porous material is disposed in the vacuum cavity. The porous materialmay comprise pre-formed core panels, or the porous material may compriseloose filler material such as powder.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an isometric view of a refrigerator including a vacuuminsulated cabinet structure;

FIG. 2 is an exploded isometric view of a vacuum insulated refrigeratorcabinet structure;

FIG. 3 is an isometric view of a vacuum insulated refrigerator cabinetstructure;

FIG. 4 is a front elevational view of the vacuum insulated refrigeratorstructure of FIG. 3;

FIG. 5 is a partially fragmentary isometric cross sectional view of thevacuum insulated refrigerator cabinet structure of FIG. 4 taken alongthe line V-V;

FIG. 6 is a partially fragmentary cross sectional view of the vacuuminsulated refrigerator cabinet structure of FIG. 4 taken along the lineVI-VI;

FIG. 7 is a fragmentary isometric view of a portion of an insulatingthermal bridge;

FIG. 8 is a fragmentary enlarged view of a portion of the insulatingthermal bridge of FIG. 7;

FIG. 9 is an isometric view of another version of the thermal bridgebreaker;

FIG. 10 is a front elevational view of the thermal bridge breaker ofFIG. 9;

FIG. 11 is a cross sectional view of the thermal bridge of FIG. 10 takenalong the line XI-XI;

FIG. 12 is a fragmentary enlarged view of a portion of the thermalbridge of FIG. 11;

FIG. 13 is a fragmentary enlarged view of a portion of the thermalbridge of FIG. 11; and

FIG. 14 is a fragmentary isometric view of a portion of the thermalbridge of FIG. 9 when assembled with a wrapper and a liner.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of the conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

The present application is related to PCT Application No.PCT/US2016/043979, filed on Jul. 26, 2016, and entitled “CONSTRUCTINGTRIM BREAKER FOR VACUUM INSULATED REFRIGERATOR USING INJECTION MOLDINGAND EXTRUSION PROCESS,” now International Patent Application PublicationNo. WO 2018/022006, and PCT Application No. PCT/US2016/043983, filed onJul. 26, 2016, and entitled “VACUUM INSULATED STRUCTURE TRIM BREAKER,”now International Patent Application Publication No. WO 2018/022007. Theentire contents of these related applications are hereby incorporated byreference.

With reference to FIG. 1, a refrigerator 1 includes a vacuum insulatedcabinet structure 2 having one or more openings 4 and 4A that may beclosed off by doors 6A, 6B, and/or 6C. The doors 6A and 6B in theillustrated example are pivotably mounted to the cabinet structure 2whereby the doors 6A and 6B pivot between open and closed positions. Inuse, a user grasps handles 8A and 8B to selectively open and/or closethe doors 6A and 6B in a known manner to provide access to arefrigerated compartment 10 through upper opening 4. In the illustratedexample, the door 6C comprises a sliding drawer having a handle 8C thatprovides access to a freezer compartment 12.

Door 6A may optionally include an ice and/or water dispenser 14. It willbe understood that various sizes, shapes, and types of doors (pivoting,sliding, etc.) may be utilized in connection with vacuum insulatedcabinet structure 2 as required for a particular application.

A refrigerator system 15 cools the compartments 10 and 12. Therefrigeration system 15 may comprise a known system including acompressor, condenser, expansion valve, evaporator, conduits, and otherrelated components (not shown). Alternatively, the refrigeration system15 may comprise thermoelectric components (not shown), or other suitablearrangement.

With further reference to FIG. 2, the vacuum insulated cabinet structure2 includes a wrapper 18 and a liner 20 that is disposed inside wrapper18 when assembled. As discussed below in connection with FIGS. 9-14,cabinet 2 may optionally include a horizontal partition and upper andlower liners 20A and 20B to form upper and lower compartments 10 and 12,respectively. As discussed in more detail below, the vacuum insulatedcabinet structure 2 also includes a thermal bridge 22 that interconnectswrapper 18 and liner 20 when assembled. As also discussed below, wrapper18, liner 20, and thermal bridge 22 form a vacuum cavity 110 (FIG. 6)that is filled with a vacuum core material 112. Vacuum core material 112may comprise a plurality of preformed individual core panels 112A-112G(FIG. 2) that are preformed and positioned between wrapper 18 and liner20 during assembly prior to attachment of thermal bridge 22.Alternatively, as discussed below, vacuum core material 112 may comprisesilica powder or other suitable loose filler material that is inserted(e.g. blown) into vacuum cavity 110 after wrapper 18, liner 20, andthermal bridge 22 are assembled. Wrapper 18 may be formed from sheetmetal thermoplastic polymer, or other suitable material. The wrapper 18may be generally bathtub-shaped and may include upper and lower sides24A and 24B, vertical sides 26A and 26B, and an upright rear side 28.Lower side 24B may include a step-like structure 30 having horizontaland vertical portions 30A and 30B that define an exterior space 32 thatis configured to receive the components of refrigeration system 15 (FIG.1). The vertical sides 26A and 26B may be generally rectangular as shownin FIG. 1 to close off exterior space 32 such that the exteriorcomponents of refrigerator system 15 cannot be seen from front and sidesof refrigerator 1. Wrapper 18 includes a first opening 34 and a firstedge 36 extending around the opening 34. First edge 36 may include upperhorizontal portion 36A, lower horizontal portion 36B, and verticalportions 36C and D that extend between upper and lower horizontalportions 36A and 36B, respectively. Thus, in the illustrated example thefirst opening 34 and first edge 36 are generally quadrilateral. However,it will be understood that the wrapper 18 may have a variety shapes asmay be required for a particular application. Wrapper 18 may be madefrom sheet metal, polymer, or other suitable materials.

If wrapper 18 is made from sheet metal, the wrapper 18 may be formedutilizing known steel forming tools and processes (not shown).Alternatively, wrapper 18 may be formed from a polymer material. Forexample, wrapper 18 may be fabricated by thermoforming a sheet ofthermoplastic polymer material. The wrapper 18 may be constructed of amaterial that is substantially impervious, such that oxygen, nitrogen,carbon dioxide, water vapor, and/or other atmospheric gasses are sealedout of vacuum cavity 110 that is formed between wrapper 18 and liner 20as discussed in more detail below. As discussed in more detail below, ifwrapper 18 is formed from a polymer material, the polymer material maycomprise a plurality of layers, wherein the layers of material areselected to provide impermeability to gasses.

The liner 20 is preferably made from a polymer material in the form of asheet that is thermoformed. The polymer material may comprise one ormore layers of material that are selected to provide impermeability togasses. The liner 20 includes upper and lower sides 38A and 38B, uprightsides 40A and 40B, and an upright rear side 42. Liner 20 includes a step44 with horizontal and vertical portions 44A and 44B. Step 44 of liner20 is configured to fit around step 30 of wrapper 18. Liner 20 mayoptionally include a plurality of reinforcing structures such as ridges46. Ridges 46 may provide for mounting of shelves or the like (notshown) in the refrigerator 1.

Examples of layered polymer materials that may be utilized to constructwrapper 18 and/or liner 20 are disclosed in U.S. patent application Ser.No. 14/980,702, entitled “MULTILAYER BARRIER MATERIALS WITH PVD ORPLASMA COATING FOR VACUUM INSULATED STRUCTURE,” filed on Dec. 28, 2015,now U.S. Pat. No. 10,610,985, and U.S. patent application Ser. No.14/980,778, entitled “MULTI-LAYER GAS BARRIER MATERIALS FOR VACUUMINSULATED STRUCTURE,” filed on Dec. 28, 2015, now U.S. Pat. No.10,018,406, the entire contents of which are incorporated by reference.Specifically, the wrapper 18 and/or liner 20 may be thermoformed from atri-layer sheet of polymer material comprising first and second outerstructure layers and a central barrier layer that is disposed betweenthe outer layers. The outer layers and the barrier layer may comprisethermoplastic polymers. The barrier layer may optionally comprise anelastomeric material. The outer layers and the barrier layer may becoextruded or laminated together to form a single multi-layer sheetprior to thermoforming. The outer structural layers may comprise asuitable thermoplastic polymer material such as High Impact Polystyrene(HIPS) or Acrylonitrile, Butadiene and Styrene (ABS), Polypropylene orPoly Butylene Teraphthalate or Polyethylene. The barrier layer maycomprise a thermoplastic polymer material that is impervious to one ormore gasses such as nitrogen, oxygen, water vapor, carbon dioxide, etc.such that the wrapper and/or liner 18 and 20, respectively provide abarrier to permit forming a vacuum in vacuum cavity 110. The barrierlayer preferably comprises a material that blocks both oxygen and watervapor simultaneously. Examples include Polyvinylidene Chloride (PVdC),high barrier nylon, or liquid crystal polymer. The thickness of thebarrier layer may be adjusted as required for different applications tomeet varied requirements with respect to oxygen and water vaportransmission rates. The materials are selected to have very goodthermoforming properties to permit deep draw ratio thermoforming ofcomponents such as wrapper 18 and liner 20 and other vacuum insulatedrefrigerator structures. Typically, the outer layers have a thickness ofabout 0.1 mm to 10 mm, and the barrier layer(s) have a thickness ofabout 0.1 mm to 10 mm.

The following are examples of material combinations that may be utilizedto form a tri-layer sheet of material that may be thermoformed tofabricate wrapper 18 and/or liner 20:

Example 1: HIPS/PVdC/HIPS Example 2: HIPS/Nylon/HIPS Example 3:HIPS/MXD-6 Nylon/HIPS Example 4: HIPS/MXD-6 Nylon with Clay Filler/HIPSExample 5: HIPS/Liquid Crystal Polymer/HIPS

A quad-layer sheet having first and second outer layers and two barrierlayers may also be utilized to form wrapper 18, and/or liner 20 Theouter layers may comprise HIPS, ABS, or other suitable polymer material(e.g. Polypropylene or Poly Butylene Teraphthalate or Polyethylene) thatis capable of being thermoformed. The first barrier layer may comprise athermoplastic polymer material that is substantially impervious to watervapor. Examples of thermoplastic polymer or elastomeric materials forthe first barrier layer include fluoropolymer such asTetrafluoroethylene (THV), polychlorotrifluoroethylene (PCTFE), CyclicOlefin Copolymer (COC), Cyclic Olefin Polymer (COP) or high densitypolyethylene (HDPE). The second barrier layer may comprise athermoplastic polymer that is substantially impervious to oxygen.Examples of thermoplastic polymer materials include ethylene vinylalcohol EVOH. An optional tying layer comprising a thermoplastic polymermaterial may be disposed between the two barrier layers. The optionaltie layer may be utilized to bond the two barrier layers to one another.Examples of suitable materials for the tie layer include adhesiveresins, such as modified polyolefin with functional groups that arecapable of bonding to a variety of polymers and metals.

The following are examples of material combinations that may be utilizedto form a quad-layer sheet:

Example 1: HIPS/EVOH/HDPE/HIPS Example 2: HIPS/EVOH/COP/HIPS Example 3:HIPS/EVOH/COC/HIPS Example 4: HIPS/EVOH/THV/HIPS THV Example 5:HIPS/EVOH/PCTFE/HIPS

The four layers may be coextruded or laminated together to form a singlesheet of material prior to thermoforming to fabricate wrapper 18 and/orliner 20.

Liner 20 includes a second opening 48 and a second edge 50. The secondedge 50 may include linear portions 50A-50D such that second opening 48is generally quadrilateral. The liner 20 is preferably somewhat smallerthan wrapper 18 to thereby form vacuum cavity 110 (FIG. 6) between liner20 and wrapper 18 when liner 20 is positioned inside wrapper 18. Also,edges 36 and 50 are spaced apart to form a gap “G” (FIG. 6).

The vacuum insulated cabinet structure 2 also includes a thermal bridge22. When cabinet structure 2 is assembled, thermal bridge 22 connects tothe first edge 36 of wrapper 18 and to second edge 50 of liner 20 tothereby interconnect the wrapper 18 and liner 20 and to close off thegap “G” formed between first edge 36 and second edge 50 when wrapper 18is positioned inside liner 20. Thermal bridge 22 is preferably formedfrom a suitable material (e.g. a polymer such as Nylon, Poly VinylChloride (PVC), or Polybutylene Terephthalate (PBT)) that issubstantially impervious to gasses to maintain a vacuum in vacuum cavity110, and also having a low coefficient of thermal conductivity to reduceor prevent transfer of heat between wrapper 18 and liner 20. Thermalbridge 22 may be formed utilizing molding processes, and may include aplurality of layers of material to provide the necessary impermeability.For example, thermal bridge 22 could comprise the same layers as thewrapper 18 and liner 20 discussed above. Thermal bridge 22 is preferablyconfigured to have a maximum allowable oxygen permeation of 10 cc/m² perday, a maximum allowable water vapor permeation of 10 g/m² per day.These maximum allowable rates are generally at one atmosphere, and atroom temperature. It will be understood that lower permeation rates arepreferred, and the rates discussed above are preferred maximum rates.However, materials providing rates higher than these preferred maximumscould also be utilized. Also, the material of thermal bridge 22preferably has a coefficient of thermal expansion that is 4.0×10⁻⁵ orlower, can withstand at least 6% strain (more preferably 35% or higher)and at least 1.0 MPa stress (more preferably 7.0 PMa or higher). It willbe understood that thermal bridge 22 could be made from materials havingproperties above or below the specific preferable numerical valuesdiscussed above. When refrigerator 1 (FIG. 1) is in use, wrapper 18 istypically exposed to room temperature air, whereas liner 20 is generallyexposed to refrigerated air in refrigerator compartment 10 or freezercompartment 12. Because thermal bridge 22 is made of a material that issubstantially non-conductive with respect to heat, the thermal bridge 22reduces transfer of heat from wrapper 18 to liner 20.

Thermal bridge 22 may include four linear portions 22A-22D that areinterconnected to form a ring-like structure having a quadrilateralperimeter 52 and a quadrilateral inner edge or surface 54 that defines aquadrilateral opening 56. The opening 56 generally corresponds to theopening 4 (FIG. 1) of cabinet structure 2. It will be understood thatthe thermal bridge 22 may have various shapes and configurations as maybe required for a particular application.

With further reference to FIGS. 3 and 4, when vacuum insulated cabinetstructure 2 is assembled, the liner 20 is positioned inside wrapper 18,and thermal bridge 22 is connected to the first edge 36 of wrapper 18and to the second edge of liner 20.

With reference to FIGS. 5 and 6, a central portion 58 of thermal bridge22 includes a central wall or web 60 and U-shaped first and second endportions 62 and 64, respectively. The materials arranged in end portions62 and 64 are generally U-shaped to form first and second channels 66and 68, respectively. The first edge 36 of wrapper 18 may include atransverse wall or flange 74, FIG. 6, and an end flange portion 76 thatis received in first channel 66. The transverse portion 74 permits theouter surface 82 of wrapper 18 to be flush with outer surface 84 ofthermal bridge 22. Similarly, second edge 50 of liner 20 may include atransverse portion 78 and an end flange or portion 80 that is receivedin second channel 68. The offset 78 permits outer surface 86 of liner 20to be flush with outer surface 88 of thermal bridge 22. The end flanges76 and 80 may optionally include raised portions 72. The raised portions72 may comprise dome-like dimples, ridges, or the like.

Referring to FIG. 6, first channel 66 is generally U-shaped, andincludes a base surface 90 and inwardly-facing opposite side surfaces92A and 92B that extend transversely away from base surface 90.Similarly, second channel 68 includes a base surface 94 and first andsecond inwardly-facing opposite side surfaces 96A and 96B that extendtransversely away from base surface 94. A plurality of tapered bosses 70extend inwardly from the side surfaces 92A and 92B of first channel 66,and from side surfaces 96A and 96B of second channel 68.

As shown in FIGS. 7 and 8, the bosses 70 may be staggered or offset. Forexample, as shown in FIG. 7, a first boss 70A may extend into channel 66from side surface 92A of channel 66, and a second boss 70B may extendinto channel 66 from second side surface 92B. The bosses 70A and 70B arepreferably spaced-apart such that a pair of bosses are not positioneddirectly across from one another on the opposite sidewalls 92A and 92Bof first channel 66. Similarly, as also shown in FIG. 7, second channel68 may include a boss 70B that extends inwardly from side surface 96B ofchannel 68, and a second boss 70C that extends into channel 68 from sidesurface 96B. Thus, the bosses 70B and 70C of second channel 68 are alsospaced-apart or staggered, such that a pair of the bosses do not extendinto second channel 68 directly across from one another.

As shown in FIG. 8, bosses 70 may include a main portion 100 having agenerally cylindrical outer surface, and a tapered end/ramp portion 98.The bosses 70 may optionally include a raised ridge 102 that extendsacross base surface 90 of first channel 66 and/or base surface 94 ofsecond channel 68.

During assembly, liner 20 is inserted into wrapper 18, and thermalbridge 22 is positioned on the first and second edges 36 and 50 ofwrapper 18 and liner 20, respectively. As the thermal bridge 22 isattached, the first and second edges 36 and 50 slide into first andsecond channels 66 and 68, respectively. The tapered bosses 70 ensurethat the edges 36 and 50 are positioned away from the side surfaces 90Aand 90B of first channel 66 and side surfaces 96A and 96B of secondchannel 68. If the edges 36 and 50 include dimples 72, the dimples 72also ensure that the first and second edges 36 and 50 of wrapper 18 andliner 20, respectively, are not positioned directly against the sidesurfaces 92A, 92B and 96A, 96B in regions between bosses 70. The taperedbosses 70 ensure that gaps 104A and 104B (FIG. 6) are formed betweenfirst edge 36 of wrapper 18 and side surfaces 92A and 92B of firstchannel 66 (FIG. 6). Tapered bosses 70 also ensure that gaps 106A and106B are formed between second edge 50 and side surfaces 96A and 96B ofsecond channel 68. Optional bases 102 (FIG. 8) may be utilized to ensurethat edges 36 and 50 do not abut the bases 90 and 94 of channels 66 and68, respectively.

After the first and second edges 36 and 50, respectively, are positionedin first and second channels 66 and 68, respectively, curable sealant108 is poured or injected into first channel 66 and second channel 68 tofill the gaps 104A, 104B and 106A, 106B. End flanges 76 and 80 of firstand second edges 36 and 50, respectively, are substantially encapsulatedby the curable sealant 108. The curable sealant 108 is allowed to cureto thereby seal the vacuum cavity 110 formed between wrapper 18 andliner 20. As shown in FIG. 6, the thermal bridge 22 generally extendsacross the gap “G” formed between the first and second edges 36 and 50of wrapper 18 and liner 20, respectively.

After the wrapper 18, liner 20, and thermal bridge 22 are assembled, theresulting subassembly may be positioned in a vacuum chamber (not shown),and porous filler material 112 may be introduced into vacuum cavity 110through an opening 114. A plurality of openings 114 may be formed inwrapper 18 and/or liner 20 as may be required to provide forintroduction of filler material 112. Filler material 112 may comprise aloose powder such as silica powder, or other suitable material.Alternatively, the filler material 112 may comprise preformed vacuumcore panels 112A-112G (FIG. 2) that are positioned between wrapper 18and liner 20 at the time liner 20 is inserted into wrapper 18 (i.e.before thermal bridge 22 is installed). Gaps between vacuum core panels112A-112G may be filled with polyurethane foam or other suitablematerial. It will be understood that filler material 112 may comprisevirtually any suitable material such as fiberglass, open or closed cellfoam, or the like. Suitable plugs 116 or the like are then inserted intothe openings 114 and sealed, and the cabinet structure 2 is then removedfrom the vacuum chamber.

With further reference to FIGS. 9-11, a thermal bridge 122 includes arectangular perimeter 124 and a divider 126 that forms an upper opening4A and lower opening 4B. The thermal bridge 122 is configured to provideupper and lower openings 4A and 4B that provide access to an upperrefrigerated compartment 10 (FIG. 1) and a lower freezer compartment 12.An upper liner 20A attaches to an upper portion 128 of thermal bridge122 that is above divider 126, and a lower liner 20B attaches to a lowerportion 130 of thermal bridge 122 that is below divider 126.

With further reference to FIG. 12, thermal bridge 122 includes a firstchannel 132 that receives first edge 36 of wrapper 18, and a secondchannel 134 that receives second edge 50 of liner 20. The channels 132and 134 may include a plurality of tapered bosses 70 that position thefirst and second edges 36 and 50 in the channels 132 and 134 duringassembly. The channels 132 and 134 may be filled with sealant 108 insubstantially the same manner as described in more detail above inconnection with FIGS. 5 and 6. The perimeter 124 of thermal bridge 122includes a central web or wall 136 that extends in a generally four-aftdirection whereby the first and second channels 132 and 134 are offsetin a fore-aft direction relative to each other by a distance “D.” Thus,the liners 20A and 20B utilized in connection with the thermal bridge122 have edges 50A that are offset inwardly relative to edges 36A ofliner 18.

With further reference to FIG. 13, horizontal divider 126 includes apair of parallel first channels 132 that extend along a front side 138of thermal bridge 122, and a pair of parallel channels 134 that extendalong a rear side 140 of thermal bridge 122. Edges 50A of upper andlower liners 20A and 20B are received in channels 134, and edges 142 ofa cap strip 144 are received in channels 132.

With further reference to FIG. 14, during assembly the liners 20A and20B are positioned inside wrapper 18, and thermal bridge 122 isconnected to the edges 36A and 50A of wrapper 18 and liners 20A and 20B,respectively. As shown in FIG. 14, thermal bridge 122 may have a J-shapein cross section. As noted above, the first and second channels 132 and134 may include a plurality of tapered bosses 70 that are substantiallysimilar to the bosses of thermal bridge 22. The bosses 70 ensure thatthe edges 36A and 50A are positioned in central portions of the firstand second channels 132 and 134. The edges 36A and 50A may optionallyinclude a plurality of raised dimples 72 that also ensure that the edges36A and 50A are not positioned directly against a side surface of achannel 132 or 134. The channels 132 and 134 are filled with curablesealant 108, and the cabinet structure is placed in a vacuum chamber. Avacuum cavity 110A formed between wrapper 18 and liners 20A and 20B isthen filled with filler material such as filler panels 112A-112G (FIG.2) or lose filler material 112 as discussed in more detail above inconnection with FIG. 6. Thus, filler material 112 may comprise porous,loose filler material such as silica powder that is inserted through anopening 114 while the cabinet structure is in a vacuum chamber.Alternatively, the filler material 112 may comprise preformed corepanels 112A-112G that are positioned between the wrapper 18 and liners20A and 20B during the assembly process (e.g. before thermal bridge 122is connected to the wrapper 18 and liners 20A and 20B).

It is to be understood that variations and modifications can be made onthe aforementioned structures and methods without departing from theconcepts of the present device, and further it is to be understood thatsuch concepts are intended to be covered by the following claims unlessthese claims by their language expressly state otherwise.

What is claimed is:
 1. A method of making a vacuum insulatedrefrigerator structure, the method comprising: forming a wrapper from asheet of material whereby the wrapper has a first opening and a firstedge extending around the first opening; forming a liner from a sheet ofmaterial whereby the liner has a second opening and a second edgeextending around the second opening; positioning the liner inside thewrapper with the first and second edges being spaced apart to form afirst gap therebetween, and to form a cavity between the wrapper and theliner; positioning a thermal bridge across the first gap, wherein thethermal bridge includes an elongated channel having a base surface andside surfaces extending transversely from the base surface, theelongated channel includes a plurality of locating structures protrudinginwardly from the opposed side surfaces; inserting a selected one of thefirst and second edges into the channel; causing the selected one of thefirst and second edges to contact at least one locating structure as theselected one of the first and second edges is inserted into the channelto form edge gaps on opposite sides of the selected one of the first andsecond edges and the side surfaces of the channel; positioning curablesealant in the channel in the edge gaps on opposite sides of theselected one of the first and second edges; curing the curable sealantto form an airtight seal; causing porous material to at least partiallyfill the cavity between the wrapper and the liner; forming a vacuum inthe cavity; and sealing the cavity to maintain the vacuum.
 2. The methodof claim 1, wherein: the thermal bridge includes first and secondchannels, each including a locating structure; and including: insertingthe first edge into the first channel; inserting the second edge intothe second channel; and positioning curable sealant in the first andsecond channels.
 3. The method of claim 1, wherein: the thermal bridgecomprises a polymer material that is substantially impervious to gasses.4. The method of claim 3, wherein: the thermal bridge has an oxygenpermeation of no more than 10 cc/m² per day, and a water vaporpermeation of no more than 10 g/m² per day.
 5. The method of claim 3,wherein: the thermal bridge comprises polymer material having acoefficient of thermal expansion of no more than 4.0×10⁻⁵.
 6. The methodof claim 1, wherein: the locating structures include tapered surfacesthat are configured to guide the selected one of the first and secondedges towards a center of the channel; and including: causing theselected one of the first and second edges to engage the locatingstructures as the selected one of the first and second edges is insertedinto the channel, wherein the selected one of the first and second edgesis centered in the channel when fully inserted in the channel.
 7. Themethod of claim 1, wherein: the at least one locating structurecomprises a tapered boss.
 8. The method of claim 2, wherein: thelocating structures in the first and second channels comprise taperedbosses.
 9. The method of claim 1, wherein: the locating structures arestaggered whereby locating structures are not positioned directly acrossfrom one another on the side surfaces.
 10. The method of claim 1,wherein: the first gap is ring-shaped; the thermal bridge is ring-shapedand including: positioning curable sealant in the first channel beforethe ring-shaped insulating thermal bridge is positioned across thering-shaped first gap.
 11. The method of claim 1, including:thermoforming the liner from a sheet of thermoplastic polymer material;forming the wrapper from sheet metal; and molding a ring-shaped thermalbridge from a polymeric material.
 12. The method of claim 1, including:positioning the opening of the liner to face in a forward direction;positioning linear portions of the first and second edges atsubstantially the same fore-aft position; and at least a portion of thethermal bridge has a U-shape in cross section, and includes elongatedfirst and second channels extending along opposite ends of the U-shape.13. The method of claim 1, including: offsetting at least a portion ofthe second edge inwardly relative to the first edge; and wherein: atleast a portion of the thermal bridge has a J-shape in cross section;and the thermal bridge includes elongated first and second channelsextending along opposite ends of the J-shape.
 14. The method of claim 1,wherein: the porous material comprises at least one core panel; andincluding: positioning the core panel in the cavity before the thermalbridge is positioned across the gap.
 15. The method of claim 1, wherein:the porous material comprises powder; and including: introducing theporous powder material into the cavity after the thermal bridge ispositioned across the gap.
 16. A method of making a vacuum insulatedrefrigerator structure, the method comprising: forming a wrapper from asheet of material whereby the wrapper has a first opening and a firstedge extending around the first opening; forming a liner from a sheet ofmaterial whereby the liner has a second opening and a second edgeextending around the second opening; positioning the liner inside thewrapper with the first and second edges being spaced apart to form a gaptherebetween, and to form a cavity between the wrapper and the liner;positioning a thermal bridge across the gap, wherein the thermal bridgeincludes elongated first and second channels, wherein at least one ofthe first and second channels includes a base surface and spaced-apartside surfaces extending transversely from the base surface, and whereinat least one of the side surfaces includes a plurality of locatingstructures protruding into the channel, and wherein at least one of thefirst and second channels includes a plurality of locating structuresprotruding into the channel from both side surfaces; inserting the firstand second edges into the first and second channels, respectively;positioning curable sealant in the first and second channels; curing thecurable sealant in the first and second channels to form airtight sealsalong the first and second edges; causing porous material to at leastpartially fill the cavity between the wrapper and the liner; forming avacuum in the cavity; sealing the cavity to maintain the vacuum; andincluding: causing at least one of the first and second edges to contactat least one locating structure as the first and second edges areinserted into the first and second channels, respectively.
 17. Themethod of claim 16, wherein: the gap is ring-shaped; the locatingstructures are tapered such that the first and second edges of thewrapper and the liner, respectively, slidably engage the locatingstructures as the ring-shaped insulating thermal bridge is positionedacross the ring-shaped gap.
 18. A vacuum insulated refrigeratorstructure, comprising: an outer wrapper having a first opening and afirst edge extending around the first opening; a liner having a secondopening and a second edge extending around the second opening, whereinthe liner is disposed inside the wrapper with the first and second edgesbeing spaced apart to form a first gap therebetween and to form a vacuumcavity between the wrapper and the liner; a thermal bridge extendingacross the first gap, wherein the thermal bridge includes an elongatedchannel, the channel including a base surface and spaced-apart sidesurfaces extending transversely from the base surface, and wherein theside surfaces include a plurality of locating structures protruding intothe channel, and wherein at least a selected one of the first and secondedges is disposed in the channel, and wherein the locating structuresposition the selected one of the first and second edge portions awayfrom the side surfaces to form edge gaps therebetween that are filledwith sealant; sealant disposed in the channel, including the edge gaps,to seal the vacuum cavity and maintain a vacuum in the vacuum cavity;and porous material disposed in the vacuum cavity.
 19. The vacuuminsulated refrigerator structure of claim 18, wherein: the thermalbridge includes first and second channels, each having a plurality oflocating structures protruding from both side surfaces thereof.
 20. Thevacuum insulated refrigerator structure of claim 18, wherein: the firstand second edges are encapsulated by the sealant.